remedial design for silos i and 2 heel …remedial design for silos 1 & 2 heel removal and...

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REMEDIAL DESIGN FOR

SILOS I AND 2 HEEL REMOVAL AND

DECANT SUMP TANK SLUDGE REMOVAL

Revision

Prepared By

Checked By

I Approved By

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. Document No. 407 10-RP-0046 : August 27,;2003

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Prepared Under US. Department of Energy

Contract No. DE-AC24-010H20115 - - _ _ _ _ -

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Remedial Design for Silos 1 & 2 Heel Removal and 507 I

Revision

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Date

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Revision Sheet

ages Affected

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Reason for Revision

Issued for Remedial Design

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Remedial Design for Silos 1 & 2 Heel Removal and

Decant Sump Tank Sludge Removal Rev. A, August 27,2003 5071

TABLE OF CONTENTS .

ACRONYMS ........................................................................................................... V . . . .

1 .o 2.0

3.0

4.0

5 .O - .. -

6.0

EXECOTlVE SUMMARY ................................................................................. BACKGROUND .................................... ;........;.............................................2-1 . .

2.1 .. ALTERNATIVE SELECTED. FOR SILOS 1 AND 2 HEEL REMOVAL ............ 2-1' . . 2.2 . . METHOD FOR REMOVING K-65 MATERIAL FROM DECANT PORTS.;

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...... 2-2 2.3.. 'ALTERNATIVE SELECTED FOR DECANT SUMP TANK SLUDGE

REMOVAL ................ ........................................................................... .

OVERVIEW ............... ;....,~...~.................r.........................,.,.......................~.3-1 . . '

3;i SEQUENCE OF OPERATIONS ..................... ........................................... . .

3.2 HEEL REMOVAL ENDPOINT.; .........................r..................................... 3-2 . 3.3 AWR SUPPORT SYSTEMS .. .................................................................. ...

. . . . 3.3.1 3.3.2

3.3.4 3.3.5 3.3.6 EQUIPMENT TESTING AND OPERATIONAL TRAINING ........................... 3-4

Silos Waste Retrieval System (SWRS) ....................................... 3-3 Transfer Tank System ................ ....'............ ; ...................... ....3-4

....... ............................... . . . . . 3.3.3 TTA Waste Retrieval System (TWRS) ; 3-4 Radon Control System (RCS) .................................................. .3-4 Process Water .System ............................................................ 3-4 Breathing Air System ............................................................ .3-4

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3.4 . .

.SILOS' HEEL REMOVAL USING MODIFIED HAZLETON PUMP WITH SLURRY . .

MODULE ............,...-......................;...........................................................4-1

4.1 SYSTEM DESCRIPTION .....................................................................4-1 4:l.l 4.1.2

Slurry Pump and Slurry Module .................................. ............. .4-2 4.2 SYSTEM OPERATION ..... ..................................................................... Sluicers and Sluicer Modules ..................................................... 4-3.

SILOS HEEL REMOVAL USING SLURRY JET PUMP WITH SLURRY MODULE ...... 5-1 ........ . . . . . .. . - - - - - - ~. -~ ..... - ~ . .. .~~ . . . . _ _ . -- - ._ .~

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5.'1 . SYSTEM DESCRIPTION .....................................................................5-1 5.2 SYSTEM OPERATION ............................................................................. SILOS HEEL REMOVAL USING REMOTELY OPERATED VEHICLE AND SLURRY . . JET. PUMP WITH HEEL RETRIEVAL MODULE ............... ;...............................6-1

6.1.7 Heel Retrieval Module ....: ....................................................... 6-2 . . .

6.1.2 ROV Platform ....................................................................... 6-2

SWRS Sluicers and ROV Sluicer with Slurry Jet Pump ................ 6-4 SWRS Sluicers, ROV Sluicer, ,ROV Plow, and.Slurry Jet Pump ...... 6-4 ROV Spray Nozzle, ROV Plow, and Slurry Jet Pump .................. .6-4

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6.1 SYSTEM DESCRIPTION ..........................................,..........................6-1

6.1.3 ROV Attachments .........................:.......................................6-3

6.2.1 6.2.2 6.2.3

6.2 SYSTEM OPERATION .........................................,.,,.............,,.........,.6-3

DECANT PORTS CLEANING ..........:.............................,.........~.....................7-1 . 7.0

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5 0 7 1 ' . Remedial Design for

Silos.1 & 2 Heel Removal and Decant Sump Tank Sludge Removal

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7.1 SYSTEM DESCRIPTION .....................,.........................~.................~....7-1 . . 7.2 SYSTEM OPERATION .....,........~........................................................7-1~ . :

SILOS FINAL WATER WASH OF INTERIOR WALLS AND FLOOR .......................... 8.1 SYSTEM 'DESCRIPTION ........................ ~..........................................'..8-1 8.2

. . . . SYSTEM OPERATION .. ;,......,..............................~.................~...........8-1 . . . . . .

. . SILOS GROUTING .......,....................................~.......~.............'..,,.~.........~..~..9-1 . . _

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9.1. SYSTEM DESCRIPTION..;...................................................~..............9-1 . . . . 9.2 SYSTEM OPERATION ............................................................................ . . . . .

DECANT SUMP TANK SLUDGE REMOVAL ...............................;.....;.....;.;....10-1 . . . .

10.1 . SYSTEM. DESCRIPTION ..................................................................... -1. 10,2 SYSTEM OPERATION ........;........r.... .................................................. 10-1

. . REFERENCES ~,,.~..,.,,........,,.........'..........................,...~,....:....................~......1 . . 1-1 . .

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Remedial Design for , . ' . Silos 1 & 2 Heel Removal and

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ALARA AWR D&D DOE FCP IP LSA NTS PPE RCS ROV SWRS TTA TWRS

ACRONYMS

As low as reasonably achievable Accelerated Waste Retrieval Decontamination and decommissioning Department of Energy Fernald Closure Project Industrial package Low specific activity Nevada Test Site Personal protective equipment Radon Control System Remotely operated vehicle Silos Waste Retrieval System Transfer Tank Area TTA Waste Retrieval System

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Remedial Design for . Silos 1 81 2 Heel Removal and

Decant Sump Tank Sludge Removal Rev. A, august 27,2003 .

1 .O EXECUTIVE SUMMARY

This remedial design document describes the system design concept for Silos I and 2 heel removal and decant sump tank sludge removal. The heel is the waste that remains in the silos upon completion of bulk waste retrieval. The objective of heel removal is to clean the silos to acceptable levels for decontamination and decommissioning (D&D) operations, Debris removal from the silos will be performed during D&D.

The decant sump tank located between Silos 1 and 2 contains a sludge comprised of K-65 material. The objective of sludge removal is to clean the decant sump tank to acceptable levels for D&D. Debris will remain in the decant sump tank and will be removed together with the tank during D&D.

Several consecutive steps are included in the remedial design for silos heel removal and decant sump tank sludge removal. These steps are:

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Silos heel removal using modified Hazleton pump with slurry module.

Silos heel removal using slurry jet.pump with slurry module.

Silos hed removal using remotely operated'vehicle (ROW and slurry'jet . . . pump . with.h'eel, . .

retrieval. module.

Decant ports cleaning.

Silos final water wash of interior walls and floor.

Silos grouting.

Decant sump tank sludge removal;

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It is expected that not all of these steps will be required to remove the heel successfully. The approach taken for heel removal will be decision based. After the performance of each step, an assessment will be made to decide whether performance of the next step is necessary. For example, the je t pump may remove sufficient heel material in Step 2 so that deployment of an ROV in Step 3 may not be needed. This step-wise approach provides for multiple contingencies. Equipment for each step will be available at the stan of heel removal operations for potential deployment if needed.

To determine the endpoint for heel removal, criteria to guide the decision-making process are required. There are three points a t which heel removal operations could potentially be stopped: (1) when the amount of residual K-65 material is low enough that the Radon Control System (RCS) is not needed to control radon emissions, (2) when the amount of r-esidual Kr65 -material can be shipped Jogeth-er -with the silo-rub_ble (wjtho-ut grouting) as- - low specific activity (LSA) 1 material, and ( 3 ) when the amount of residual K-65 material is reasonable for grouting to achieve criteria for shipment as LSA-1 material. When making decisions during heel removal, tradeoff costs, schedule constraints, and regulatory requirements associated with treatment, packaging, shipping, and disposal will be taken into consideration. As low as reasonably achievable (ALARA) principles will also be considered. The project will not stop heel removal simply because operation of the RCS is no longer required. Continued removal of heel material for as long as is practical will

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Decant Sump Tank Sludge Removal Rev. A, August 27, 2003

reduce the exposure of workers during D&D operations. Section 3.2 discusses the logic of the decision-making process to determine the final endpoint for heel removal.

Heel material will be removed from one of the silos (either Silo 1 or 2) following Steps 1 through 6, if the steps are needed, and then these steps will be repeated for removal of heel material from the other silo. Systems and equipment (e.g., sluicers, pumps, piping, tanks, cameras, etc.) used by the Accelerated Waste Retrieval (AWR) Project for bulk waste retrieval will be used to support heel and sludge removal operations. Several of the steps (Steps 1 through 5) will continue to use the existing sluicer modules to mobilize the heel material. The heel material removed from the silos will be transferred to the Transfer Tank Area ( lTA) tanks for subsequent treatment in the Remediation Facility.

The first step in the silos heel removal sequence of operations is to use the existing bulk retrieval system to the maximum extent possible with the existing Hazleton slurry pump, which will be modified to achieve additional depth. Sluicing with the existing Silos Waste Retrieval System (SWRS) sluicers will be continued to mobilize the heel material. When the modified Hazleton pump reaches its limit for heel removal (based on loss of suction due to limited liquid depth, i.e., minimum submergence), Step 2 will be implemented and a different pump's inlet will be placed in the silo sump.

The second heel removal step is to position a slurry jet pump's inlet in the silo sump. The slurry je t pump will be deployed using the existing slurry module following removal of the Hazleton slurry pump. The slurry jet pump will convey the heel material out of the silo. The heel material will then be transferred to the TTA storage tanks with the assistance of a slurry booster pump to be installed within the slurry module on the bridge. The slurry je t pump can continue to operate until the silo sump is pumped nearly empty. Therefore, the slurry jet pump is expected to be able to remove almost all of the heel material that can be moved by the SWRS sluicers to the silo sump.

The third heel removal step will add use of an ROV to the equipment being used in Step 2. The northern and southern sides of the silos are expected to have areas of heel that will not be easy to mobilize due to their distance from the SWRS sluicers, the angle of attack of the water streams, and the geometry of the silos,__The ROV will be used in combination with the SWRS sluicers to move this heel material to the silo sump. As in Step 2, a slu-rry jet pump's inlet will be positioned in the silo sump, and it will convey the heel material out of the silo and then to the TTA storage tanks with the assistance of a slurry booster pump. To deploy the ROV, a specially designed heel retrieval module will be used, which will replace the existing slurry module. The ROV and heel retrieval module will be supplied by a vendor that will design and construct the equipment in accordance with a performance specification prepared for-the Fernald heel removal application.- - - - - -

For the fourth step, K-65 material will be cleaned from the silo decant ports by one of two methods. If the silo berm is in place at the time of this step, then the ports will be sheared from the silo interior wall, fall to the silo floor, and be washed using the sluicer nozzles. If the berm is removed prior to this step, then the ports will be cleaned by flushing water from the outside of the silo through the weir and baffle assembly. The K-65 material and wash water will be removed from the silo in the same manner as heel material is removed.

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5 0 7 1 Remedial Design for

Silos 1 & 2 HeelRemoval and Decant Sump Tank Sludge Removal

Rev. A, August 27, 2003 . . ,

In the fifth step, heel removal will include a final water wash of the silo interior walls and floor. The SWRS sluicers and ROV water broom will be used for this operation. If, after completion of th is step, the K-65 material remaining in the silos has reached an acceptable level, then this will be the last step of heel removal, and the silos will be turned over for D&D operations.

The sixth step will be implemented in the event that sufficient K-65 material could not be removed during heel removal Steps 1 through 5 to reach acceptable levels of residual heel material. The system will consist of contractor supplied and operated equipment for mixing and grouting the remaining K-65 material in place within the silo. A performance specification will be prepared for the grouting step. The concept is based on grouting demonstrations with simulated residual wastes in test tanks at Department of Energy (DOE) sites. It was demonstrated that the grout can be uniformly mixed with the residual material to produce a homogeneous product and the grouting tools are applicable to tanks as large as 85 ft in diameter. The amount of grout to be blended will be sufficient to reduce the concentration of radionuclides to ensure that the resulting grouted waste material will meet LSA-1 criteria for shipment.

The seventh step, removal of sludge containing K-65 material from the decant sump tank, will be performed by a contractor in accordance with a performance specification prepared for this scope of work. During meetings with commercial tank cleaning vendors, a concept to clean the decant sump tank was determined. The concept is a combination of mixing and pumping for several cycles t o remove the sludge. Removal o f the silo berm overlying the decant sump tank would increase the range of mixing and pumping technologies that could be used, and therefore, may be advantageous prior t o contracting for this work. Removal of the overlying berm t o allow closer access t o the decant sump tank would occur after bulk waste and heel removal operations were completed. The sludge removed from the decant sump tank may be transferred to the TTA tanks for subsequent treatment in the Remediation Facility, or the sludge may be treated separately by an alternative treatment that complies with Nevada Test Site (NTS) waste acceptance

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Decant Sump T a n k Sludge Removal Rev. A , August 27, 2003

2.0 BACKGROUND

Silos 1 and 2 are located at the U.S. Department of Energy (DOE) Fernald Closure Project (FCP) site near Cincinnati, Ohio. The silos presently contain K-65 material, a residue generated from processing high-grade uranium ores, which contains radionuclides including radium (the primary contaminant of concern). The silos also contain BentogroutO caps, which cover the K-65 material to reduce radon emanation. The purpose of the Accelerated Waste Retrieval (AWR) Project is to retrieve the K-65 and BentogroutO materials contained in the silos and transfer them to the Transfer Tank Area (TTA) tanks for staging prior to their transfer to the Silos 1 and 2 Remediation Facility for treatment.

The heel is the waste that remains in the silos upon completion of bulk waste retrieval. The objective of heel removal is to clean the silos to acceptable levels for decontamination and decommissioning (D&D) operations. Debris removal from the silos will be performed during D&D. In addition to Silos 1 and 2, a nearby underground decant sump tank (9,000 gal capacity) contains approximately 1,000 gal of sludge comprised of K-65 material. The K-65 material was entrained in decant water and transferred to the decant sump tank during silo filling operations, which were accomplished using a slurry and decant process. The objective of sludge removal is to clean the decant sump tank to acceptable levels for D&D. The small amount of K-65 material in the sludge removed from the decant sump tank will be treated either in the Remediation Facility or separately by an alternative treatment. The alternative treatment would differ from the Remediation Facility's treatment process, b u t it would convert the sludge into a form that complies with the Nevada Test Site (NTS) was te acceptance criteria for disposal as well a s with applicable transportation regulations. Debris will remain in the decant sump tank and will be removed together with the tank during D&D.

2.1

A workshop was held January 21-22, 2003, with a team of experts f rom DOE facilities and- private-hdustry to-develop and evaluate alternatives for-heel removal from the Fernald - - Silos 1 and 2. Constraints on silos heel removal were discussed first; brainstorming of alternatives followed; alternatives were refined next; and lastly, screening criteria were used to rate the alternatives. Additional background information can be found in Silos Heel and Decant Sump Tank Sludge Removal Technical Report, Document No. 407 70-RP- 0037. The four highest rated alternatives from the workshop and their ability to be implemented with the existing Silos Waste Retrieval System (SWRS) were then examined. The results of this analysis are contained in Silos I And 2 Heel Removal Alternatives, Document No.

ALTERNATIVE SELECTED FOR SILOS 1 AND 2 HEEL REMOVAL

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407 IO-RP-0038.

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507 1. The recommendations from analysis of the heel removal alternatives include: (I) modification of the Hazleton pump to maximize its ability to remove heel material (by reducing its submergence requirements), (2) replacement of the Hazleton pump with a jet pump with its inlet located in the silo sump, and (3) use of a remotely operated vehicle (ROV) (with plow and water nozzle tools) to ensure that all heel material is mobilized and moved to the sump. In addition, this ROV could position the je t pump inlet in the sump and move debris to an out-of-the-way location near the silo wall.

DOE'S Office of Science and Technology performed a task to evaluate the current availability and capabilities of ROVs with potential for application to Fernald heel removal operations. ROVs, both within the DOE system and available commercially, were examined. Although refurbishment of an existing DOE ROV was considered, the evaluation (Ref. 1) concluded that a new ROV should be procured for use at Fernald.

2.2 METHOD FOR REMOVING K-65 MATERIAL FROM DECANT PORTS

Alternatives for removing K-65 material from the silo decant ports were also discussed in the workshop and were examined further in Silos 7 And 2 Heel Removal Alternatives, Document No. 407 70-RP-0038. The recommended method for cleaning the decant ports depends on whether the silo berm is still in place when the work is conducted. If the silo berm is in place, the method involves removing the decant port weir boxes from the interior wall (shearing was later selected) and washing the piping and weir boxes with the sluicers. If the berm has been removed, the method involves cleaning the ports by flushing water from the outside of the silo through the weir and baffle assembly. In either case, the K-65 material and wash water will be removed from the silo in the same manner as heel material is removed.

2.3 ALTERNATIVE SELECTED FOR DECANT SUMP TANK SLUDGE REMOVAL

Alternatives for removing K-65 material from the decant sump tank were also discussed during the workshop. It was determined that discussions with commercial tank cleaning vendors would be valuable in developing a recommended approach. Meetings with five vendors were held May 28, 2003, to discuss their capabilities and ideas for removing K-65 sludge from the decant sump tank. The current strategy-is to use a contractor to perform this scope of work. A performance specification will be prepared during preliminary design for the contractor scope of work. It is expected that the contractor will propose to use a combination of mixing and pumping, for several cycles, to clean the decant sump tank.

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Remedial Design for . '

Silos 1 & 2 Heel Removal and Decant Sump Tank Sludge Removal

Rev. A, August 27, 2003 '

3.0 OVERVIEW 50 7 1- The scope of this document includes system design descriptions of the remedial design for Silos 1 and 2 heel removal and decant sump tank sludge removal. The heel and sludge removal operations will be accomplished in several steps, which are described in separate sections of this document.

3.1 SEQUENCE OF OPERATIONS

Several consecutive steps are included in the concept for silos heel removal and decant sump tank sludge removal. These steps are:

1. Silos heel removal using modified Hazleton pump with slurry module.

2. Silos heel removal using slurry jet pump with slurry module.

3. Silos heel removal using remotely operated vehicle (ROV) and slurry jet pump with heel retrieval module.

. 4. Decant ports cleaning.

5. Silos final water wash of interior walls and floor.

6. Silos grouting.

7. Decant sump tank sludge removal.

It is expected tha t not all of these steps will be required to remove the heel successfully. The approach taken for heel removal will be decision based. After the performance of each step, an assessment will be made to decide whether performance of the next step is necessary. For example, the je t pump may remove sufficient heel material in Step 2 so that deployment of an ROV in Step 3 may not be needed. This step-wise approach provides for multiple contingencies. Equipment for each step will be available a t the start of heel removal operations for potential deployment if needed.

Heel material will be removed from one of the silos (either Silo 1 or 2) following Steps 1 - _ through 6, if the steps are needed, and then these steps will be repeated for removal of

heel material from the other silo. Step 7, decant-sump tank sludge removal, will follow Step 6 and will be preceded by excavation of a portion of the silo berm.

For bulk waste retrieval operations, each silo has its own dedicated equipment. For heel removal operations, each silo will still have use of this bulk waste retrieval equipment as needed. However, for new heel removal equipment, only one set of new equipment will be required because the equipment will be deployed sequentially. The new heel removal equipment will be deployed at one of the silos (either Silo 1 or 21, and then the equipment will be moved and deployed at the other silo. Simultaneous heel removal operations in both silos will not be possible because of electrical power and sluice water volume constraints. There may be a period of transition between bulk waste retrieval and heel removal operations, Equipment that will be required for heel removal after such a transition period will be maintained in a condition that will support its restart at a later date.

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Decant Sump Tank Sludge Removal Rev. A, August 27.2003

5071 3.2 HEEL REMOVAL ENDPOINT

To determine the endpoint for heel removal, criteria to guide the decision-making process are required. Figure 1 depicts the logic for making decisions during heel removal operations, The project has determined that a suitable bounding criterion for the cessation of further heel removal operations is when radon emissions from the residual material are low enough that the Radon Control System (RCS) does not need to operate to control these emissions, This is the situation when the radon emission rate is low enough that both workers and the public are protected without further controls. If the radon emission rate is not sufficiently low, then more heel material will be removed, and additional equipment will be deployed using the step-wise approach.

The project will not stop heel removal simply because operation of the RCS is no longer required, Continued removal of heel material for as long as is practical will reduce the exposure of workers during D&D operations. ALARA principles will be considered during the decision-making process.

If an excessive amount of heel material remains in the silo, then the rubble produced during D&D will not be able to be shipped as LSA-1 waste. If the D&D rubble containing heel material cannot be classified as LSA-I waste, it would be classified as LSA-I1 waste, and an industrial package (IP) 2 container would be required for transport. An IP-2 container is an engineered container that must meet several criteria including a 3-ft drop test without the loss of any contents. It would either be necessary to package the D&D rubble in the container being used for the Remediation Facility (1 8-in. diameter opening), or a new IP-2 container would need to be designed, tested, and qualified. This would be impractical from both a cost and schedule basis.

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'Next, the amount of.residua1 heel material would be assessed to determine if it would be practical for grouting, which would involve adding an amount of grout that would' be

' sufficient to reduce the concentration of radionuclides to meet criteria for .LSA-I material. The additional inert material would need to be reasonably homogeneously mixed with the K-65 material for it to be classified as'LSA-1 waste. If grouting were impractical, then

At some 'point, the airflow from the silos to the RCS could be turned off and the residual heel material, with or without grouting, could .be shipped'as LSA-I waste. A t this point; the decision could be made to discontinue.hee1 removal operations and'turn the silo over for D&D operation's. . .

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.-additional.. equipment w.ould~ be deployed for further heel removal operations. - - - --- -~ - -_ -. . _ _ ~ - - -- -- - - - -

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Remedial Design for Silos .1 &.2 Heel Removal and

Decant Sump Tank Sludge Removal Rev. A, August 27; 2003 .

3 0 7 1 . . Figure 1 . . ,

3.3 AWR SUPPORT SYSTEMS

The following systems, provided by the AWR Project for bulk waste retrieval, will be used to support heel and sludge removal operations.

3.3.1 Silos Waste Retrieval System (SWRS)

SWRS will use the technique of "past practice sluicing" to retrieve and transfer bulk waste material from the silos. The SWRS sluicers and their corresponding sluicer modules will be used during Steps 1 through 5 of silos heel removal for mobilizing heel material, rinsing debris, and washing the silo walls. The SWRS Hazleton slurry pump will be modified (to reduce submergence requirements) and used during Step 1 of silos heel removal operations to remove heel material from the silo and transfer it to the TTA tanks. The SWRS slurry

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Remedial Design for Silos 1 81 2 Heel Removal and


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5 4 7 1 module will be used during Steps 1 and 2 to house and deploy heel removal pumps. Other SWRS equipment, such as the bridge monorail hoist, the diverter valve enclosure, and the diverter valve enclosure winch will also be used during heel removal operations. The double-contained 4-in. diameter transfer pipeline will be used for transferring heel material to the TTA tanks.

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Three closed-circuit television video cameras with lights, which will be deployed through risers in each silo roof to provide an overall view required to maneuver and control in-silo equipment during SWRS, will also be used during heel removal operations.

3.3.2 Transfer Tank System

Heel material removed from the silos will be transferred to and staged in the transfer tank system storage tanks before' it is ultimately transferred, using the TTA Waste Retrieval System (IWRS), to the Remediation Facility for treatment.

3.3.3 TTA Waste Retrieval System (TWRS)

During heel removal operations, the TWRS slurry/decant pumps will be used to provide sluice water to the silo sluicers, in the same manner as during SWRS operations. Sluice water will be recycled from the TTA tanks, where a settling and decant process will be used to recover the water.

3.3.4 Radon Control System (RCS)

The RCS provides ventilation and reduces radon concentrations in the silos and other tanks containing K-65 material and residues. ' During heel removal operations, it will provide ventilation through the silos. During decant sump tank cleaning operations, ventilation can also be provided by the RCS as needed.

3.3.5 Process Water System

Process water from three makeup water tanks will be supplied during heel and sludge removal operations as needed. Clean water will be required to decontaminate heel removal equipment and other items as they are retracted from the silos. The process

-water system-can provide high-pressure (3,000 psi) water for decontamination operations. Process water may also be used in Step Sfor accomplishing the final-water-wash of the silo interior walls and floor, After use, the water will be transferred to the TTA tanks for subsequent treatment in the Remediation Facility.

3.3.6 Breathing Air System

Breathing air is available for personnel entering the equipment modules for maintenance and other activities (e.g., Steps 1 and 2 retrofit). Breathing air would be provided by the existing breathing air system.

3.4 EQUIPMENT TESTING AND OPERATIONAL TRAINING

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- Prior to the introduction of new heel removal equipment into the silos, equipment testing will be performed, Present plans call for an equipment test period of approximately one- month duration followed by a training period of approximately three months. During the training period, operators will simulate various aspects of the heel removal operations. The testing and training will be carried out on the same Fernald Test Stand that will be '

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' Remedial Design for Silos 1 & 2 Heel Removal and

Decant Sump Tank5ludge Removal Rev. A, August 27, 2003

5071 used to test equipment for bulk waste retrieval. The testing and training will be preceded by development of testing and training plans and will lead to the finalization of heel removal procedures.

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Decant Sump Tank Sludge Removal Rev. A, August 27,2003

5071 4.0 SILOS HEEL REMOVAL USING MODIFIED HAZLETON PUMP WITH SLURRY

MODULE

The first s tep in the silos heel removal sequence of operations is to use the existing bulk retrieval system to the maximum extent possible with the Hazleton vertical, centrifugal slurry pump, which will be modified to achieve additional depth. The slurry pump will be modified for heel removal after reaching its limit for bulk retrieval, which is dictated by the initial height of the pump stand and submergence requirements.

The SWRS pump stand extension and intake screen will be removed and replaced with a "suction saver" intake screen to initiate heel removal operations. Pump modifications are described in greater detail in Section 4.1.1. The intake screen will be the shortest Hazleton recommends based on the minimum screen open area needed for minimum recommended pump flow. Theoretically, with this configuration, minimum submergence can be reduced to 1-1/2 to 2 in. Flow will need to be reduced when the bottom of the screen is blocked during this type of operation to minimize cavitation. Cavitation will be indicated in the control room by sudden reduced flow, surging flow, reduced current draw on the pump motor, or a combination of all three. This modification increases risk of damage to the pump since it may tend to cycle between cavitation and no cavitation. The reduced flows might also result in slurry transfer pipe plugging. Reduction in the slurry solids content and close attention to pump operation will greatly minimize these risks. It is expected, based on conversations with the pump manufacturer, that the level of damage sustained by the pump will not significantly reduce pump performance, much less cause pump failure, during the amount of time the pump will be operated in this configuration. The pump damage, if any, would be sustained only during the latter phases of operation when the bottom of the pump screen is resting completely on the bottom of the silo. This will occur only during the final pump down of the slurry. An insignificant amount of damage is expected in the short duration of this operation.

The thickness of the heel would reach about 5 in. in the vicinity of the pump with the standard inlet screen and pump feet after removal of the SWRS pump stand extension.

- _ _ With the planned modifications, t he heel thickness should be reduced to approximately 1.5 in. Redis-will b e dependent on the techniques that operating personnel employ during - - - operation of the SWRS sluicers and the modified SWRS slurry pump when the heel thickness approaches the theoretical minimum. Sluicing with the existing SWRS sluicers will be continued to mobilize the heel material following modification of the SWRS slurry pump. When the modified slurry pump reaches its limit for heel retrieval, it will be removed from the silo and slurry module. A jet pump will then be deployed through the slurry module to be used in Step 2 (Section 5.0). The jet pump's inlet will be positioned in the silo sump for improved heel removal efficiency.

4.1 SYSTEM DESCRIPTION

The first step in the silos heel removal sequence of operations is to use the modified SWRS slurry pump with the existing slurry module. This system is almost the same as the bulk waste retrieval system; the only change is modification of the existing slurry pump.

-

000016 4-1



5071 The major equipment components for this step are:

Silo 1 Sluicer Module 1 (SLC-11-203)


Silo 1 Slurry Pump (PMP-11-201)

Silo 1 Slurry Module (SLR-11-201)



Silo 2 Slurry Pump (PMP-11-202)


All these equipment components will exist for bulk waste retrieval. The existing slurry pumps will be modified for heel removal operations.

4.1 .I Slurry Pump and Slurry Module

The Hazleton slurry pump is a vertical, centrifugal-style, submersible pump. It has a strainer screen mounted under and around the pump feet, ahead of the pump suction, to limit the size of material entering the pump. Oversized objects would lodge in the pump impeller and cause damage to the pump. The pump will be modified for heel removal operations by removing the pump stand and reducing the screen opening area. The SWRS pump stand is designed by Hazleton to maintain pump inlet clearance dimensions during SWRS operations yet allow minimum pump inlet clearances for heel removal. This has been achieved by reducing the pump foot height and installing spacers integral to the SWRS pump stand and intake screen.

Prior to heel removal activities, the pump will be raised into the slurry module and the SWRS pump stand will be replaced with the suction saver screen. Activities required to complete replacement are limited to removal of the pump inlet spray ring and removal and replacement of the pump stand and intake screen. Replacement of the pump stand and

--intake screen- is -achieved by removing- and replacing only three attachment bolts. The modification may take a s long a s one shift to complete because the work will occur within the slurry module with personnel wearing personal protective equipment (PPE). The slurry pump will be used to transfer heel material out of the silo and to the TTA tanks, and will operate at about 200 psi and 350 gpm. The slurry pump has a variable speed drive to control flow rate. The elevation of the slurry pump can be adjusted along the entire vertical profile of the silo by a chain hoist.

---- ----- The sturc.y-p_u~p Mill be deployed thr_o_u$_h_ the center riser into thKsll_o !EF-tke- e_is!ng- _ _ _ _ _ - slurry module. The module is a sealed steel structure that provides secondary containment. The slurry module is located in the center of the silo and is supported by the bridge structure. The module is about 8 f t wide by 19 f t long by 15.5 f t high and weighs about 20,500 Ib. The module contains the equipment needed to allow the pump to be operated with minimal or no routine personnel access. This equipment includes a chain hoist, one hose reel to hold the pump discharge hose, one hose reel for the high-pressure

- - _ _

000027 4-2

. . . . .



'

-50 7 1 water supply hose (for the pump inlet spray ring), one cable reel to hold pump power wiring, one cable reel for instrumentation cable, and piping/hoses and valves to direct flows.

A decontamination spray ring, supplied with high-pressure water (3,000 psi) from the high-pressure water pump, will be used whenever the slurry pump is retracted into the module. Process water will be available to the module as a backup to sluice water for flushing t h e slurry line following a transfer. In addition, process water will be available to back-flush the slurry pump. Both of these backup provisions are implemented using jumper hose connections.

4.1.2 Sluicers and Sluicer Modules

Two SWRS sluicers with sluicing nozzles, deployed from two sluicer modules, will be used to mobilize the heel material in each silo. Each sluicer is supplied with sluice water by the TTA decant pumps. The sluicers will use low to medium pressure (about 150 psi), high volume (about 250 to 300 gpm) sluice water to dislodge heel material, form a slurry, and convey heel material to the intake of the slurry pump. Whether one or two sluicers are operated, the total sluicing flow rate is fixed, with a maximum total f low of about 300 gpm, to maintain a water balance in the silo.

A mast supports the sluicer nozzle, sluice water supply hose, and power and control cables. The mast hoist (cable-type hoist) in each of the sluicer modules can adjust the nozzle assembly elevation. Additional sections of mast can be attached to enable the sluicer nozzles to be positioned at lower elevations.

The sluicer modules provide secondary containment. They are located on either side of the slurry module and are supported by the silo bridge structure. The sluicers are deployed through risers along the silo's perimeter at 0" and 180" and approximately 50 f t apart. Each sluicer module is about 6 ft wide by 10 ft long by 20 ft high and weighs about 13,500 Ib.

Each sluicer module is equipped with a decontamination spray ring, supplied with high- pressure water (3,000 psi) from the high-pressure water pump, which will be used whenever a sluicer and/or mast is retracted into the module. -

Cameras with lights, located in three risers on each silo dome, will be used to view the progress of the sluicing and heel removal operations.

4.2 SYSTEM OPERATION

Initially, one sluicer nozzle stream will be directed as close to the slurry pump inlet as possible to create a slurry pool and form a cavity for slurry to flow into. The modified slurry pump will be lowered into the cavity and started. The sluicer will then begin p ~ s ~ r n g + ~ e l t e r i s ~ f o W a ? d l ~ ~ pmF white- avai&ng-ctme-cwtact with the-plrmpinlet; -- --- -- Cavitation and loss of pump prime can occur when sluice water impinges on the pump intake screen. Typically, one sluicer will be operated at a time, and the sluicers will be alternated as needed. Both sluicers could be operated at once to attempt to mobilize certain "dead zones" of heel material.

-------

4-3



50 7 4 5.0 The second s t e p in the silos heel removal sequence of operations is to use a slurry jet pump, with its inlet located in the silo sump, in combination with the existing slurry module after t h e modified Hazleton pump has been removed from the module. The slurry jet pump can continue to operate until the silo sump is pumped nearly dry. Therefore, the slurry jet pump is expected to be able to retrieve almost all of the heel material that can be moved by the sluicers to the silo sump (to a thickness in the sump of about 34 in.).


This heel removal step uses a slurry jet pump, with its inlet located in the silo sump, with the existing slurry module. A slurry booster pump will be installed in t he slurry module to transfer the heel material to the TTA storage tanks.

The major equipment components for this step are:






Silo 2 Slurry Module (SLR-11-202) Slurry Jet Pump (PMP-11-301)

Slurry Booster Pump (PMP-11-302)

The sluicer and slurry modules will exist for bulk waste retrieval. The primary reasons for selecting the jet pump for this application include its lighter weight, compact size, limited need for additional support equipment for operation, absence of moving parts within the pump, ability to function without cavitation while solids are agitated a t the pump suction, control of discharge slurry density to some degree, and ability to remove solids down to a thickness of approximately % in, The white paper titled Pump Selection for Silos 7 and 2 Heel Retrieval, included as Appendix A of Silos 7 And 2 Heel Removal Akernatives, Document No. 40710-RP-0038, . provides additional information on selection of the jet Pump* The slurry jet pump will be deployed from the existing slurry module, located in the center of the silo, The slurry jet pump body will be positioned adjacent to the silo sump, which is slightly offset from the silo's center. The jet pump will be designed with an inlet extension

was used by the centrifugal slurry pump to provide the capability for remote vertical adjustment. The l i f t chain and pump hoses will be threaded through smooth sleeves and/or pulleys, which will be attached to the slurry module support steel with hand operated "come-alongs" or similar tensioning devices. After deployment of the jet pump into the silo through the central access riser, the tensioning devices will be used to draw the hoist chain and pump hoses to the edge of the central riser. This will position the

SILOS HEEL REMOVAL USING SLURRY JET PUMP WITH SLURRY MODULE

______ t h a t w il I - r eachin ta t he sump- Jb e pumpwill besu p pockd fmmtheaame-chainbpisl that

5-1

5071 nemedial uesign lor . . .


Rev. A, August 27, 2003 .

pump adjacent to the silo sump. Additional cables may need to be attached to the pump and routed to the module for adjustment of the pump inlet location.

The slurry j e t pump will use sluice water as its motive force a t approximately 175 gpm and 150 psig. In passing through the je t pump, the motive force water will entrain the slurried heel material. The suction flow rate of the slurry jet pumc will be approximately 155 to 175 gpm. The discharge pressure of the jet pump is conservatively estimated to be about 23 psig. The slurry jet pump will transfer the heel material as a slurry to the slurry booster pump mounted within the slurry module. The slurry booster pump is anticipated to be a 60 HP centrifugal pump. The slurry booster pump will transfer the heel material slurry to the TTA storage tanks through the existing 4-in. diameter transfer piping system. The slurry je t pump will provide approximately 330 to 350 gpm a t about 4 psig pressure to the booster pump inlet.

The slurry je t pump will be equipped with an agitator ring with multiple water nozzles. The nozzles will emit water jets in a turbulent manner around and adjacent to the pump inlet to improve heel material mobilization. The water je t nozzles are rudimentary in design and use large diameter orifices (1/8 in. to 1/4 in. diameter), which have little risk of plugging. .The nozzles will use the same sluice water as used for the jet pump motive force. The agitator nozzles are designed for use only when the jet pump flow falls below normal and agitation is desired or deemed necessary by operating personnel.

The slurry je t pump is submersible and its inlet cart be run dry without damage to the pump. Due to the nature of the pump design and operation, flushing the slurry discharge line is accomplished either by allowing the pump to run until the sump is nearly empty or by raising the pump out of the slurry, eliminating the slurry inlet stream, The.sluice water supply fluid then flushes the line because no more slurry is entering it. Process water will be available to the slurry module as a backup to sluice water for flushing the slurry line following a transfer. In addition, process water will be available to back-flush the booster pump. Both of these backup provisions are implemented using jumper hose connections. The slurry module decontamination spray ring, supplied with high-pressure water (3,000 psi) from the high-pressure water pump, will be used to clean the jet pump whenever it is retracted into the module.

Two SWRS sluicers will be used to mobilize the heel material in each silo. Lower flow sluicer nozzles will be used 1% in. nozzles will be replaced) since the je t pump requires sluice water for operation. The nozzles are designed to maintain sluicing effectiveness with the reduced flow. Each sluicer is supplied with sluice water by the TWRS slurry/decant pumps. The sluicers will operate a t approximately 100 gpm and 150 psig, if used one a t a time while the slurry jet pump is operating.

Each sluicer module is equipped with a decontamination spray ring, supplied with high- pressure-water 43;OOO psi)-frm-the-high=pressure tmter-pwnpT -which- will-be-used -to- ---- -

clean the equipment whenever a sluicer and/or mast is retracted into the module.

Cameras with lights, located in three risers on each silo dome, will be used to view the progress of the sluicing and heel removal operations.

-

---- --

000020 5-2

Remedial Design for Silos. 1 &' 2'Heel Removal and


5.2 SYSTEM OPERATION . 5.0 7 1: '..

. . The slurry jet pump will initially be deployed in a vertical position in the same location as the centrifugal slurry pump. After entry into the silo, the pump hoist chain and hoses will be drawn to the edge of the central riser opening. This will position the pump close to the location of the silo sump. Once in position, the pump will be lowered to rest on the heel material. Slurry and water will be pumped out to a minimum depth of approximately 34 in. at the jet pump inlet. The sluicing nozzles will then be used, either one a t a time or in unison, to move heel material to the jet pump inlet. Sluicing effectiveness will be improved for this step, as compared to the step using the modified Hazleton pump, since the water layer over the heel material can be reduced to a minimum by the jet pump without concern for losing pump prime or causing cavitation.

Typically, one sluicer will be operated a t a time, and the sluicers will be alternated as needed. However, both sluicers could be operated a t once to attempt to mobilize greater volumes of heel material. As t h e heel level in the silo decreases, the slurry jet pump will be periodically lowered into- the silo. The sluicer nozzles will also be manipulated to increase heel removal effectiveness, using their pan, tilt, and elevation control capabilities to control sluicer angle of attack. The normal operating flow rate of sluice water will be approximately 100 gpm in this step.

The combination of sluicing and pumping will remove the heel material a s slurry. Water will enter the silo through the sluicers at about 100 gpm and leave through the slurry jet pump. The combined sluice water/heel removal rate from the silo will range from about 155 t o 175 gpm. This will result in a net heel removal rate of about 55 to 75 gpm. The slurry jet pump is powered by sluice water. The jet pump requires approximately 175 gpm of sluice water to move the slurry out of the silo. The total discharge flow out of the silo to the slurry booster pump will range from 330 to 350 gpm.

The pump will be lowered, as heel removal from the sump rapidly progresses, until the pump inlet reaches the bottom of the sump or downward movement is halted by debris or dense solids. Heel material will be directed toward the sump by the sluicers until heel removal effectiveness is deemed marginal. The pump's water nozzle-type agitator will be used during these activities when necessary.

000021

5-3

. .

Remedial Design for . ,


Rev. A, August 27,2003

' .

50'7 I- 6.0 SILOS HEEL REMOVAL USING REMOTELY OPERATED VEHICLE AND

. . . . SLURRY JET PUMP WITH HEEL RETRIEVAL MODULE .

The third heel removal step will add use of a remotely operated vehicle (ROV) to the equipment being used in Step 2. The ROV will be used in combination with the SWRS sluicers to move heel material to the silo sump. A slurry jet pump's inlet will be positioned in the silo sump, in the same manner a s used in Step 2, and the jet pump will be used to convey the heel material out of t he silo. The heel material will be transferred to the TTA storage tanks with the assistance of a slurry booster pump.

To deploy the ROV, a specially designed heel retrieval module will be used, which will replace the existing slurry module. Support equipment for the ROV, such as an umbilical reel, will be contained within the heel retrieval module. In addition, a new slurry jet pump and a new slurry booster pump will be used so that the complete heel retrieval module with equipment can be tested before operations. The contaminated pumps used in Step 2 for the first silo can be retained as spares or moved for installation and use in Step 2 for the second silo.

The ROV and heel retrieval module will be supplied by a vendor that will design and construct the equipment specifically for the Fernald heel removal application. Requirements for the ROV were prepared and are contained in Appendix B of SJos I 0nd 2 Heel Removal Alternatives, Document No. 407 10-RP-0038. A performance specification for the ROV will be prepared during the preliminary design for heel removal. The ROV is expected to be equipped with a plow blade, water sluicer nozzle, and water broom attachments. Prior to deployment into a silo, the ROV with its attachments will be tested on the Fernald Test Stand.


The major equipment components for this s tep are: Silo 1 Sluicer Module 1 (SLC-11-203)

Silo 1 Sluicer Module 2 (SLC-11-204) _.

~.

Silo 2 Sluicer Module 1 (SLC-11-205) - -


Silo 1 &2 Heel Retrieval Module (ENC-11-201)

Slurry Jet Pump (PMP-11-301)


Remotely Operated Vehicle (ROV-11-201) --I----- ___________-_____________ -- -- -

Hi6GUfiE PiihFr-UtiiT ~RPU-TTZCW -

The sluicer modules will exist for bulk waste retrieval. The sluicers, slurry jet pump, and slurry booster pump will be the same as described in Section 5.1.

000022

6- 1

Remedial Design for .

Silos 1 &' Z'Heel Removal and . .

Decant Sump Tank Sludge Removal Rev. A, August 27,2003 ;

6.1.1 Heel Retrieval Module 90 7-1 . A heel retrieval module will be designed to replace the SWRS slurry module on the silo bridge. The heel retrieval module will contain the umbilical, hose, and cable reels for both the ROV and the slurry jet pump. It will be equipped with many features similar to the slurry module, such as a connection for a high-efficiency particulate air filter, glove ports for operation and maintenance, personnel access doors, and piping for the discharge from the slurry jet pump. Both the ROV and the slurry jet pump will be deployed through the central access riser connected to the heel retrieval module. The module design will enable the slurry jet pump inlet to be positioned in the silo sump. The ROV will be used, if necessary, to help position the jet pump inlet in the silo sump. The jet pump will be custom made to specifications that will facilitate its proper positioning. If maintenance of the jet pump or ROV equipment is needed, the equipment will be retracted from the silo into the heel retrieval module.

Removal of t he SWRS slurry module and installation of the heel retrieval module will entail disconnection of piping and electrical service and reinstallation of those items plus additional control wiring. Lifting the existing module out will not require removal of major components, ductwork, or piping. Reinstallation of the heel retrieval module will be similar to initial installation of equipment modules on the bridges.

6.1.2 ROV Platform

The ROV will consist of an equipment platform conveyed by moving tracks, similar to those used on a bulldozer, for traction. Equipment selected for heel mobilization will be attached to this platform. The ROV will carry the attached equipment to the desired work location within the silo to move the heel toward the silo sump. The ROV platform may also be designed to accept attachments that can be used to grasp, hook, or push other materials, such a s debris and ancillary equipment, to relocate them within the silo. The ROV will use cable-connected remote control. The cable used for communication with the ROV will be deployed in a controlled manner to minimize the length of cable, to keep the cable out of the ROWS areas of operation, and to maximize the ROV's mobility. A control console will be installed in the AWR control room, and the ROV operator will use the camera monitors that were used for SWRS activities during heel removal activities. Three cameras with lights, installed in the silo for SWRS operations, will be used by operating personnel to monitor the ROV during heel removal operations.

The ROV will be hydraulically powered. Power will be transmitted to the equipment from a hydraulic power unit, located outside and adjacent to the silos, using hydraulic fluid lines. Lines will be provided both for fluid supply and for fluid return. Hydraulics will be used for both t h e drive train and for many of the platform attachments used on the ROV.

equipment so that in the unlikely event of a leak, a mixed waste will not be produced.

The ROV control cable, hydraulic lines, and water hoses will be contained in an umbilical. This umbilical will be managed on a reel within the heel retrieval module. Separate cable and hose reels for the slurry jet pump will also be housed in the heel retrieval module.

- ---_ An -environrnentaJly-sa€e, xegetable=bas_ed _by_draulic fluid will be used in the ROV

i .

6-2



. 6 . .

I e

e

. e

1.3 ROV Attachments

te ROV will be equipped with the following attachments:

Rubber-tipped Carbon Steel Plow Blade - The blade will be attached to linkages and hydraulic cylinders that will allow the blade to be positioned where needed between a low and high position. The low position will allow ground scraping, and the upper position will place the bottom of the blade high enough to allow mobility on the uneven terrain expected in the silo when the ROV is first deployed.

Water Sluicer Nozzle - A remotely adjustable water sluicer nozzle will be mounted centrally on the top of the platform. The attachment will be equipped with interchangeable nozzles so either stream or spray types could be used. The remote control will be used to adjust the pitch of the stream. Side-to-side movement will be controlled by moving the ROV platform.

Water Broom - A water broom, consisting of a number of fan-spray water jets mounted in a row like bristles on a broom, will be used to rinse and push heel material in the direction of ROV movement. Used alone or in combination with the plow blade (acting as a squeegee), residual heel that may be le f t behind by water nozzle-only cleaning will be directed to the silo sump. The water broom attachment will also be used during the final water wash of the silo floor.

Light - A waterproof, impact-resistant, high-powered light will be rigidly mounted out of harm's way on top of the platform to illuminate the work area. Three closed-circuit television video cameras with lights, deployed through risers in each silo roof for SWRS operations, will provide an overall view required to maneuver and control the ROV during heel removal operations. No camera will be mounted on the ROV because experts advised that a camera would provide little utility while increasing system complexity and frequency of equipment failure.

The performance specification for the ROV, to be prepared during preliminary design, will include requirements for all attachments. All ROV components will be required to be able t o withstand a short duration direct hit from a sluicing nozzle stream.


Following completion of the first two heel removal steps, a custom-fabricated heel retrieval module will replace the SWRS slurry module on the silo bridge. Before replacement, the slurry module will be disconnected from all piping and controls; It will then be disconnected from the silo access riser and detached from the bridge. A crane will be used to lift the slurry module off the bridge and replace it with the heel retrieval module. The ventilation system, sluice water system, and electrical and control systems will be cann-ected- tothe-heel retrieval module-after- it-is-a#ached-to -thebridge. -The44n,slury- - - ____ transfer line to the TTA will also be connected to the heel retrieval module.

Next, the slurry j e t pump will be deployed from the heel retrieval module through the central access riser, and it will be positioned adjacent to the silo sump in a manner similar t o Step 2. The ROV will then be deployed into the silo through the central access riser. If needed, the plow blade on the ROV will be used to help position the slurry jet pump and

-

-----__

6-3

Hemedial Ueslgn lor Silos 1 & 2 Heel Removal and


inlet extension in the proper orientation to the silo sump. If can be temporarily removed to allow the ROV increased redeployed when needed to resume slurry removal.

The following sections provide the expected sequence of removal step.

6.2.1 SWRS Sluicers and ROV Sluicer with Slurry Jet Pump

,5071.. needed, the slurry .jet pump mobility. It will then be .

operations during this. heel . . . . .

. . .. .

. . . ,

After the ROV is deployed, it will be used in combination with the SWRS sluicer modules and the slurry jet pump. It is expected that most of the heel material will be recovered using t h e SWRS sluicers to move the heel to the silo sump. Areas on the northern and southern sides of the silos are expected to have areas of heel that will not be easy to mobilize due to their distance from the SWRS sluicers, the angle of attack of the water streams, and the geometry of t h e silos. The ROV will be positioned in these areas, and the ROV water sluicer nozzle will initially be used to cut a preferential trench through the heel to help the SWRS sluicers move the heel to the silo sump. If there is debris that is hampering movement of the heel or blocking the slurry jet pump, the plow blade on the front of the ROV will be used to move the debris to an out-of-the-way location. The plow blade may also be used at this stage if operating personnel determine it will help accelerate heel mobilization.

- ---- ~ ~ ~ - S ~ ~ - ~ u ~ c ~ ~ S t u ~ ~ ~ r ~ R O V P l a w ~ a n d -Slurry-SetPump-- ---------- ------ - - -

Once the heel thickness allows the ROV to gain adequate traction on the silo floor, the ROV's plow will be used to accelerate heel removal by pushing heel material either to areas where the sluicers are effective in moving it to the silo sump or to the silo sump directly. At this point in the operation, it is expected that the silo sump location will be uncovered, and the slurry jet pump inlet will be positioned directly in t he sump to increase the heel removal effectiveness. The water sluicer nozzle on the ROV will still be in use during this phase of removal, and the plow blade can be positioned for SWRS sluicer deflectionhedirection if necessary.

6.2.3 ROV Spray Nozzle, ROV Plow, and Slurry Jet Pump

Once the bulk of the heel material is retrieved, the ROV sluicer will be remotely converted to a spray nozzle. The spray will be used in conjunction with the plow to rearrange and rinse off debris located within the silo. Once the debris is adequately rinsed, it will be pushed to a location near the silo wall. After the debris is consolidated in one area, the ROV with the spray nozzle will work from the perimeter of the silo inward to spray visible heel material toward the sump for removal. SWRS sluicers will not be used during this phase of the cleanup.

If sufficient heel material is removed during this step, then a final water wash of the silo interior walls and floor (see Section 8.0) will complete the heel removal operations. Decant port cleaning (Step 4) will overlap Step 3 operations (or may start during Step 2) so that the K-65 material contained in the decant ports can be removed together with the heel material. If an unacceptable amount of heel material remains, then the grouting system will be deployed (see Section 9.0).

6-4

. . .

. .

. .

Remedial Design tor

Decant Sump Tank Sludge Removal Rev. A, August 27.2003

Silos 1 & 2 Heel Removal and ' .

~ - 3 Q 7 ' 7.0 DECANT PORTS CLEANING

One of two methods will be used for.cleaning any held-up K-65 material from the silo decant ports. If the silo berm is in place at the time of this step, then the ports wilhbe sheared from the silo interior wall, fall to the silo floor, and be washed using the sluicer nozzles. If the berm is removed prior to this step, then each port will be cleaned by flushing water from the outside of the silo through the weir and baffle assembly. In either case, the K-65 material and wash water will be removed from the silo in the same manner as heel material will be removed. Decant ports cleaning will overlap Step 3 operations (or possibly start during Step 2) so that the K-65 material contained in the decant ports can be removed together with the heel material.

7. I ' SYSTEM DESCRIPTION. The major equipment components for this step are:

Guided Ram Weight .(for first. method only) ' .


Silo 2 Sluicer Module 1 (SLC-I 1-205)

.

Silo 1 Sluicer Module'l (SLC-11-203) . .

. '

I .

-- ---Silo-2-Slujcer-Modtrle 2-(SLG++--206)- - -- - - -- ---- -- - - ___ - __ - _ _ - _ _ ___ - _ _ - _ _ Silo'l&2 Heel Retrieval Module (ENC-11-201)

Slurry Je t Pump (PMP-11-3011


Remotely Operated Vehicle (ROV-11-201)

Hydraulic Power Unit (HPU-11-201)

With the exception of the guided ram weight, these equipment components are identical to those used during Step 3 of heel removal. The sluicer modules will exist for bulk waste retrieval. The heel retrieval module and other equipment will be d-eployed during heel removal Step 3.


In this step, one of two methods will be used for cleaning the decant'ports. The method selected will depend on whether the silo berm is in place a t the time of this step, and consequently, whether the ports can be accessed from the interior or exterior of the silos.

The first method will be used if the silo berm is in place. This method uses a guided ram weight dropped through a 36-in. penetration in the silo dome directly above the decant ports. The ram will shear the ports from the interior walls, and the metal weirs and baffles will be allowed to fall to the silo floor. A full-scale demonstration of the guided ram weight is planned prior to implementation of this method in the silo.

In the first method, both the sheared pieces and the pipes in the silo wall will be washed with water using the sluicer nozzles, and if needed, the ROV sluicer. The ROV can also be

0000;26

7-1


Decant Sump Tank Sludge Removal Rev. A. August 27, 2003

- -

used to move the sheared pieces to an out-of-the-way location with other debris for the remainder of heel removal operations. The decant ports are located on the east and west walls of each silo, and therefore, they are close to the sluicers (located east and west of the silo center). This will facilitate cleaning of the decant port piping in the silo walls following shearing of the weir boxes.

The second method will be used if the silo berm has already been removed. This method cleans each decant port by flushing water from the outside of the silo through its weir and baffle assembly and into the silo. The silo sluicers and ROV sluicer will not be needed for flushing the ports.

For either method, the K-65 material removed from the decant port components and the wash water will be removed from the silo in the same manner as heel removal using sluicing and pumping, and if needed, the ROV. Decant port cleaning will overlap Step 3 operations (or possibly start during Step 2) so that the K-65 material contained in the decant ports can be removed together with the heel material.

.. - . .

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7-2

. . .

Remedial Design for


Silos-1 & 2 Heel Removal and. . '

'

. . \

8.0 SILOS FINAL WATER WASH OF INTERIOR WALLS AND FLOOR so71 . .

Before turning .the silos over for D&D operatiqns, heel removal will include a final water wash of the silo interior walls and floor. If, after completion of this step, the amount of K-65 materia1,remaining in the silos is an acceptable level, then this will be the last step of heel removal. If K-65 material in excess of acceptable levels still remains in the silos, then the heel removal _. . . . grouting system will'be implemented (See Section 9.0). '

The final 'water. 'wash of the silo interior walls will be accomplished using the two SWRS . . ' . . . '

sluicers, .which were used previously during bulk .waste retrieval and ot.her steps of heel removal. .The final water wash of t h e silo floor will be accomplished using the ROV with a water broom attachment. The water from the washing process .will be collected in the silo'

booster pump in .the heel retrieval module. Debris remaining in the silo will have previously (during 'Step 3) been moved to. one location near the silo wall and rinsed with the:silo

' ' sluicers and/or the ROV water nozzle. Debris 'removal from the silos will be performed

' '

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.

. .

. , . sump and pumped to the TTA tanksusing'the jet pump with its inlet in t h e w m p and the . .

' . .

. .

. . . during D&D: ; . . . . ' . .

. . .8.1 SYSTEM DESCRIPTION ' , . ' . . .

The major equipment components for this.step are:

Silo , i Sluicer Module 2 (SLC-11-204)

Silo 2 Sluicer Module 1 (SLC-1'1-205) ' '


Silo 1842 Heel Retrieval Module (ENC-11-201)

Slurry Jet Pump (PMP-11-301)

. .

. .


Remotely Operated Vehicle (ROV-11-201) -

Hydraulic Power Unit (HPU-11-201)

These equipment components are identical to those used during Step 3 of heel removal. The sluicer modules will exist for bulk waste retrieval. The heel retrieval module and other equipment will be deployed during heel removal Step 3.


During the silo washing operation, the sluicers will be directed a t the silo walls, starting a t the top, moving in a grid-like pattern from side to side, and then moving downwards. The sluicers will operate a t approximately 100 gpm and 150 psig, if used one at a time while the slurry jet pump is operating. After the walls are washed, the silo floor will be washed using the ROV with the water broom attachment. The ROV will be moved in a systematic pattern starting a t the silo walls and "sweeping" towards the sump. If needed, t he rubber- tipped plow blade on the ROV can be used a s a squeegee. The slurry jet pump will be operated to remove the wash water from the silo, and the slurry booster pump will assist

-

8- 1


Decant Sump Tank Sludge Removal Rev. A. August 27, . .. 2003

. .

. in transferring the wash water to the TTA tanks. The .entire expected t o take approximately four hours for each silo, based on rate for.the interior silo surface area.

washing' operation ' is a reasonable washing

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8-2

' Remedial Design for . '

Silos 1 81 2 Heel Removal and ' ' . '


9.0 SILOS GROUTING In the event that sufficient K-65 material could mot be removed .during heel removal steps 1 through 5 .to reach acceptable levels, then a grouting system will be deployed, This system will consist of contractor supplied and operated equipment for mixing and grouting the K-65 material remaining in the bottom of the silo in place. A performance specification.

If unacceptable amounts of K-65 material remain in a silo'after the final water' wasti step is

be sufficient to reduce the concentration of. radionuclides to ensure that . the resulting grouted .waste material will meet LSA-1 criteria for shipment. . ._

. . for the grouting . . work will be'prepared during preliminary design. . . . .

. '

completed, the grouting system will be deployed. .The amount 'of grout to be blended' will '

9. I SYSTEM .DESCRIPTION . . .

The major equipment compo.nent for this step is:

. .

. . . . . .

. . . .

. . . .

. Grouting Skid (SKD-11-201) . .

The grouting system is based on contractor supplied and operated equipment that provides turbulent mixing and grouting of a small amount of K-65 material remaining in the bottom of the silos. K-65 material previously on the silo walls and ceiling would be washed off by the sluicers prior to this step and would be present on the floor of the silo. Assuming that about % in, of ai;/ K-65 mifei ial EmZin%& i66uuf1-365yd3 o f g-@~tTiv~~ld-bi3-blefidetJ W<t?ii--- the material in order to meet LSA-1 criteria. The resulting grout would be approximately 2 ft deep in the 80 ft diameter silo.

The concept is based on grouting demonstrations with simulated residual wastes in test tanks a t DOE sites (see Ref. 2 - 5). It has been demonstrated that the grout can be uniformly mixed with the residual material to produce a reasonably homogeneous product. The demonstrations have included use of grouting tools designed for tanks as large as 85 ft in diameter.

The concept for the contractor-supplied system is based on equipment contained on three .truck trailers. The first trailer will contain storage bins and blending equipment for dry materials (cement and fly ash): The second trailer will-contain a batch system for blending the pre-mixed dry materials with a bentonite/water mixture. The bentonite will be pre- hydrated with process water to form a 3% bentonite gel (3 Ib bentonite in 100 Ib water). ' The pre-mixed cement and fly ash will then be blended with the bentonite gel to produce a batch of grout. The third trailer will contain high-pressure pumps, hoses, and connections to introduce the grout into the silos. The grout will be rapidly pumped into the silo with sufficient force so that the grout will mix with the K-65 material to form a reasonably homogeneous product. If the K-65 material were hardened onto the bottom of the silo, sufficient force to scarify the silo floor would be required to enable the K-65 material to be mixed with the grout. The three-trailer system will be deployed near the silo on the gravel pad used previously for bridge construction. After completion of grouting the first silo (either Silo 1 or 2), the system will be moved and deployed near the second silo.

The grouted waste material will be removed from the silos during D&D operations. Therefore, it is preferable for the grouted waste material to have a lower strength than the

-

9-1

' Remedial Design for Silos.1 & 2 Heel Removal and

Decant Sump Tank Sludge Removal Rev. A, August 27, 2003 .

. . silo walls and floor. It is estimated that a grout containing about 10-20% cement an'd 80- 90%,fly ash, mixed together with 3% bentonite gel in water,. will be satisfactory for this . application. The bentonite is added to prevent the grout from producing bleed water after setting.' The grout formulation will take.into account the water present. with the residual heel material. . .

The grouted waste material will be removed during D&D by.the.same methodsused for the silo walls and floor. It is anticipated that a hoe ram (jackhammer on a.'track.-hoe) and/or a hydraulic shear will be used for demolition and that'a shovel attachment will .be


It is expected that the contractor'supplied and operated grouting system will require about , a one-week set-up period per silo and that the grouting process will take about one day

. '

. . . .

used for removing rubble and filling 'shipping containers (likely lined rail cars).. . . . . .

. .

: . . per silo to complete.

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9-2

Remedial Design for Silos 1 & 2 HeelRemoval and

Decant Sump Tank Sludge Removal Rev. A, August 27. 2003

5 0 7 1 10.0 DECANT SUMP TANK SLUDGE REMOVAL

Removal of sludge, expected to contain K-65 material, from the underground decant sump tank will be performed by a contractor. A performance specification will be prepared during preliminary design for the contractor scope of work. During previous meetings with commercial tank cleaning vendors (see Section 2.31, a concept to clean the decant sump tank was determined. The concept is a combination of mixing and pumping for several cycles to remove the sludge. Removal of the silo berm overlying the decant sump tank would increase the range of mixing and pumping technologies that could be used, and therefore, may be advantageous prior to contracting for this work. Removal of the overlying berm to allow closer access to the decant sump tank would occur after bulk waste and heel removal operations were completed. 10.1 SYSTEM DESCRIPTION The major equipment components for this step are:

Tank Cleanout Skid (SKD-11-202) Decant Sump Tank Pump (PMP-11-303) '

Several different approaches may be used to clean the decant sump tank, depending on the contractor selected. The concept will likely first use a mixing technology such as a water nozzle or pulse mixer to mobilize the sludge. Some water will likely be added to t h e tank to dilute the sludge to a pumpable mixture. After the sludge is sufficiently mixed, then the slurry will be pumped out of the decant sump tank. This water addition, mixing, and pumping cycle will be repeated several times until the tank is sufficiently cleaned. A water nozzle may be needed to rinse the tank walls, depending on the amount of residual sludge that is acceptable for tank removal during D&D operations.

The slurry from the decant sump tank can be transferred directly to the T T A tanks using the 2 in. transfer line that will be installed for SWRS operations. Rather than transferring the sludge to the TTA tanks for subsequent treatment in the Remediation Facility, the sludge-may be treated separately by an alternative treatment. The alternative treatment would convert the sludge into a form that complies with NTS waste acceptance criteria for disposal a s well a s with applicable transportation regulations. The slurry from the decant sump tank could also be transferred to a transport truck (vacuum or o the r type) prior to treatment. The contractor may elect to use t h e pump that will be installed in the decant sump tank for SWRS operations, or may provide an alternate pumping system.


The tank cleaning contractor is expected to be able to clean the decant s u m p tank within about a day. A set up time of about a week will likely be needed to deploy the mixing and pumping equipment.

t

10-1



I 1 .O REFERENCES 507 .1 . .

1.

2.

3.

S.M. Killough, B.E. Lewis, Review of Remotely Operated Vehicles and Cold Testing Alternatives for the Fernald Silos I an@ 2 Heel Retrieval Operations, Oak Ridge National Laboratory, April 30, 2003.

R.D. Spence, J.L. Kauschinger,' Grout Performance in Support of In Situ Stabifization/SolidiLication of the GAA T Tank Sludges, ORNL-TM-13389, Oak Ridge National Laboratory, May 1997.

J.L. Kauschinger, R.D. Spence, B.E. Lewis, In-situ Grouting Technology Demonstration and Field Specifications Overview for Hot Deployment of the Multi-Point Injection System in Gunite and Associated Tank TH-4, ORNLKM-13710, Oak Ridge National Laboratory, October 1998.

4. J.L. Kauschinger, B.E. Lewis, Utilkation of the MP17M Process for In-Tank So/idification of Heel Material in Large-Diameter Cylindrical Tanks, ORNL/TM-2000/8, Oak Ridge National Laboratory, January 2000.

5. J.L. Kauschinger, B.E. Lewis, R.D. Spence, FY 7999 Cold Demonstration of the Multi- Point Injection (MPI? Process for Stabilizing Contaminated Sludge in Buried Horizontal Tanks with Limited Access at Oak Ridge National Laboratory and Savannah River Site, ORNL/TM-1999/330, Oak Ridge National Laboratory, February 2000.

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11-1

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GENERAL' NOTES: . . . '

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PRELIMINARY NOT FOR CONSTRUCTION .-

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GENERAL 'NOTES: , STEP 1 INVOLVES USE OF THE WULETON PULP AT A DEEPER

. STEP 2 INVOLVES SWSTIMIHG AN EOucmR JET RBP CQ1

SUBWGWCE lNAN COR Am Buu WASTE REWAL.

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GENERAL .NOTES:

. STEP 3 M D S A REUOlELY OPERATE0 VEHICLE (ROVI TO STEP 1.

!. STEP 4 INVOLVES A M OF THE DECANT PQITS. ,

I. WD STEP FLOORS 5 ADDRESSES Cf THE FINAL SILOS. W A S H w R ( . Q m THE WALLS

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DEPARTMENT OF ENERGY FERNALD ENVLRONMENTAL U A N A G W PROJEC

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. . ZENERAL.NOTES: , '

1. STEP T INVOLVES CLEANOUT Of THE DECANT SUU' T A M M J W T 10 TWE SILOS.

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UNITED STATES DEPARTMENT OF ENERGY

FERNALD ENVWOHlllENTAl MANAQEYENT P R M m - w m n

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EOUPMENT DESCRIPTION

. . EQUIPMENT EOUIPMENT EQUIPMENT SYSTEM NUMBERING

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DESIGNATOR (XXX) DESCRIPTION (XXX) GENERAL NOTES:. .

- -507 1

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MISCELLANEOUS . .

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'EOUIPMENT . . .

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WJACOBS - -YI

EQUIPMENT NUMBER IDWTGFlCAnON OILIDOIU

FLOW tmmm PROCESS FLOW CUGRull

. . . . . . .

. . . . 5 0 7'1 . . . . . .

NOTES: . .

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. . . . . . BALANCE FOR STEP 1 (MODIFIED HAZLETON PIJMP)

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BALANCE FOR STEP 3 (REMOTELY OPERATEO' VEHICLE). . .

E UNITED STATES

DEPARTMENT OF ENERGY F E W ENVWOWEJfrAL YANAGEUEMT PROJECT

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. . BALANCE FOR STEP 5 (WALL/FLOOR WASH-DOWN)(NOTE 7 ) .

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NOTFS: 507 1

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FLOW DIAGRAMS PROCESS FLOW MAGRAM

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GENERAL NOTES: LSTREur lMf8ERS AH) fLOWS *RE lYPKK TOR BOTH S L a .

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AWR BOP OPTIMIZATION I ! l

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GENERAL. NOTES: t STIIELY W E R S UO f lBWS CIlE ,TYPIC+ FOR BOTH SILOS.

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NOTES:

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. . 2. SuIPoRT h W f S pv-11-20L I&-11-201 nmRiwc POWER W l 'TO

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AWR BOP OPTIMIZATION . . FLOW -mu. DIAGRAMS

PROCESS FLOW DIAGRAM . .

GENERAL'NOTES: . '

L S T R U WUECRS NdD fLOWS LRE 1YACLL FOR BpTH %OS.

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ERNALD ENVIRONMENTAL MANAGEMENT PROJECl 00DUlDe-u

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FLOW DIAGRAMS PROCESS FLOW DIAGRAM

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remedial design for silos i and 2 heel …remedial design for silos 1 & 2 heel removal and...

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